By replacing physical insulation with a specialised liquid coating, the newly-developed technology from Sherwin-Williams removes the environmental conditions required for CUI to develop.
Global coating manufacturer Sherwin-Williams
has unveiled a new thermal insulation coating designed to completely eliminate the threat of corrosion under insulation (CUI) for industrial assets. The product, named Heat-Flex® AEB (Advanced Energy Barrier), acts as a direct replacement for traditional, bulky mineral-based insulation systems widely used on storage tanks, process vessels, and piping.
CUI is one of the most pervasive and expensive challenges in the processing and petrochemical industries. It occurs when moisture penetrates traditional insulation materials and becomes trapped against the underlying metal, causing rapid, hidden corrosion.
Heat-Flex AEB addresses this by applying a thick film of insulative material directly to the asset. The coating is capable of maintaining process temperatures of up to 177°C, with temporary temperature spikes permissible up to 204°C.
“Corrosion under insulation requires the presence of insulation. By removing this from an asset and applying the thermal insulative coating in its place, there is no longer any physical system under which corrosion can occur. We’re kissing both insulation and CUI goodbye,” has explained Neil Wilds, Global Product Director for CUI at Sherwin-Williams Protective & Marine.
According to the manufacturer, the breakthrough offers several key environmental and operational advantages over traditional metal cladding and mineral wool setups:
- Consistent Thermal Efficiency:
Unlike conventional insulation, which progressively loses its efficiency due to inevitable moisture ingress, Heat-Flex AEB maintains a stable thermal barrier. This prevents energy waste and eliminates the need to increase process heat over time.
- Reduced Supply Chain Footprint: The solution eliminates the need to manufacture, ship, and store massive quantities of mineral wool, cladding, wiring, pins, and banding.
- Asset Longevity:
By preventing hidden corrosion, the coating extends the operational lifespan of steel assets, reducing long-term maintenance and replacement costs.
Installing traditional insulation systems often poses safety risks, requiring workers to manually wrap, band, and clad components in close proximity to hot machinery.
In contrast, Heat-Flex AEB is a 1K (one-component) spray-applied coating
that requires minimal preparation, users simply open, mix, and spray. A single coat instantly lowers the surface temperature of the asset, eliminating burn risks for personnel.
Crucially for plant operators, the coating can be applied while assets are live and operating at temperatures up to 148°C, significantly reducing operational downtime. It can also be applied to new assets in pre-assembly yards before they arrive on-site. For maximum corrosion protection, Sherwin-Williams recommends spraying Heat-Flex AEB over an approved primer applied directly to prepared steel, such as Heat-Flex 750 or Heat-Flex ACE.